Wiring device



y 22, 1952 R. o. W lLEY 3,036,171

WIRING DEVICE Filed March 24, 1959 3 Sheets-Sheet 1 R. O. WILEY WIRING DEVICE May 22, 1962 3 Sheets-Sheet 2 Filed March 24. 1959 Fig. 3.

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R. O. WILEY WIRING DEVICE May 22, 1962 3 Sheets-Sheet 3 Filed March 24, 1959 Fig.5

United States Patent 3,036,171 WIRING DEVICE Roy 0. Wiley, Bridgeport, C0nn., assignor to The Bryant Electric Company, Bridgeport, Conn., a corporation of Connecticut Filed Mar. 24, 1959, Ser. No. 801,658 10 Claims. (Cl. 200-67) The present invention relates generally to electric wiring devices and more particularly to a new and improved toggle operated mechanism wherein little movement of the toggle is required to operate a switching mechanism.

Wiring devices of contemporary design, particularly presently available toggle operated wall switches, require a toggle handle be operated through a fairly large angle in order to operate the basic switching mechanism. The conventional toggle operated devices require the toggle handle to move approximately 22 to effectuate the switching action. Furthermore, a relatively large amount of operating force is required to move the toggle handle.

The present invention relates to a new and improved switch structure which may be actuated by an elongated handle which rotates through a small angle about a center pivot point. The total angular movement for the switch actuator may be as low as 3 and not only has the actuator movement been decreased, but the operating force has also been substantially lowered. Thus, this switch construction lends itself to the use of a large plate type actuator which is capable of only limited angular movement.

Accordingly, one object of this invention is to provide a new and improved toggle operated mechanism having an actuator which is moved through a relatively small angle in order to operate the toggle mechanism.

Another object of this invention is to provide a new and improved toggle operated switching mechanism having an actuator wherein a relatively small force is required to move the actuator for operation of the switching mechanism.

A more particular object of this invention is to provide a novel electric wiring device having a rigid contact carrying member wherein a movable contact is mounted on' a resilient portion of the rigid member.

Another object of this invention is to provide a novel switch mechanism having an elongated actuator which is pivotally mounted on the switch housing, and it is provided with a pair of cam surfaces thereon to pivotally move a pair of rigid contact supporting members in a lateral direction to operate the switch mechanism.

Another object of this invention is to provide a novel switch mechanism which permits use of a large plate type handle, capable of only limited angular movement.

Still another object of this invention is to provide a novel switch mechanism having a pair of elongated rigid members mounted in end-to-end relationship and biased inwardly toward each other and having a member of insulating material engaging the inner ends of each of said rigid members.

These and other objects of this invention will be more apparent from a review of the following detailed description of a specific embodiment of the invention-along with the attached drawings, in which:

FIGURE 1 is an exploded isometric view of a wiring device constructed in accordance with the principles of the instant invention;

FIG. 2 is an enlarged topplan view of a wiring device shown in FIG. 1 having the actuator and the upper housing removed;

FIG. '3 is an enlarged longitudinal sectional view of the switch shown in FIGS. 1 and 2 and having the contact carrying members shown in one stable position;

FIG. 4 is an enlarged plan view of the undersides of the upper housing and switch actuator;

FIG. 5 is a sectional view of the wiring device shown in FIGS. 1 through 4 and taken substantially along the reference line V-V of FIG. 3;

FIG. 6 is a view in end elevation of the switch shown in FIGS. 1 through 5 having certain portions cut away for clarity and taken substantially along the reference line VI-VI of FIG. 3;

FIG. 7 is a sectional view of a wiring device constructed in accordance with the principles of this invention showing the contact carrying members in another stable position and employing a different stationary contact therein; and

FIG. 8 is an enlarged isometric view of one of the stationary contacts utilized in the embodiment of the invention shown in FIG. 7.

A wiring device constructed in accordance with the principles of this invention may comprise a generally cupshaped lower housing 10 formed from a suitable insulatingmateri'al such as a molded insulating material. The lower housing 10 is formed to contain a pair of combined terminal and biasing members 12 therein together with a pair of combined stationary contact and terminal members 14. The members 12 and 14 are preferably formed from a suitable electrically conductive material having both strength and resilient properties, such as a copper alloy. The members 12 are provided with integral resilient portions or projections 16 which are located to extend outwardly from the open side of the lower housing 10 adjacent an end wall 18. A pair of rigid movable contact supporting members or levers 20 and 22, formed from a resilient conductive material, such as the aforementioned copper alloy, is adapted to be mounted in an end-to-end relationship and located adjacent the open side of the lower housing 10. A member or barrier 24 of insulating material, or conductive material if circuit control objectives permit, can be provided, in separate form if desired and as shown here, with a pair of opposed grooves 26 on opposite side walls thereof. An inner edge 28 of the lever 20 is located in one of the grooves 26, and an inner edge 30 of the lever 22 is'locate'd in the other groove 26. An edge 32 of the outer end of the lever 20' is adapted to engage a projection 34 on the resilient portion 16 of one of the terminals 12 so that the lever 20 is resiliently held between the barrier 24 and the engaged resilient portion 16. Similarly, an intermediate edge 36 of the lever 22 is formed to engage a projection 34 on the other resilient portion 16 so that the lever 22 is held between the barrier 24 and the resilient portion 16 of the other terminal 12.

When the levers 20 and 22 are assembled in the aforesaid manner, it is to be noted that the distance between the resilient portions or projections 16 on the opposed terminal members 12 is slightly smaller than the distance between the outer edges 32 and 36 of the'levers 20 and 22, respectively, when the barrier 24' is located therebetween. Thus, it may be seen that, as the levers 20 and 22, as well as the barrier 24 if desired, are rigid, the resilient projections 16 are forced laterally so that a longitudinal force is created along the levers 20 and 22. Movement of the levers 20 and 22 into the housing can be effected by placing a downward force on an intermediate portion of the lever 20, and movement of the levers 20 and 22 in the opposite direction is achieved by subjecting the lever 22 adjacently of its outer edge 38 to a downward force. Accordingly, by properly locating con tacts in the housing and on the levers 20 and 22, respectively, it may be seen that a switching action can be performed. As will be described more fully hereinafter, the switching action can be achieved with relatively little movement of an actuating member.

Referring particularly to FIGS. 1 through 6, it is to be" noted that the lower housing 10 is provided with two ter minal openings 40 located in each of a pair of side walls 19 thereof. The openings 40 include portions 42'which extend inwardly along the base of the housing 10 and are provided so that a lead wire may be inserted upwardly into the housing through the opening portions 42 to engage the terminals of the wiring device. The pair of combined terminal and biasing members .12 are mounted in opposed relation at opposite ends of the lower housing 10. A terminal portion 44 of each member 12 is provided with an openingv therethrough to locate the stem' of a terminal screw 46 therein, so that the enlarged head of the terminal screw 46 engages one side of the terminal portion 44. The shank of the terminal screw 46 is preferably threaded and'is adapted-to be threadedly received in a threaded opening 48 of a clamping plate 50. The head of the terminal screw 46 is constructed to be larger than the opening 40 in the side wall of the housing 10, and the terminal screw 46 and clamping plate 50 are assembled to the terminal portion 44 of the member 12 before the latter is assembled with the lower housing 10. The lower housing 10 is provided with a recess adjacent the terminal openings 40 to receive the terminal screw 46 and the terminal plate 50. An elongated groove 52 is formed in the housing adjacent the inner surface of each end wall 18 by means of raised portions 54' which oppose each end wall 18.

Each terminal member 12 is provided with a laterally extending portion 56 from which the resilient projections 16 extend, and the lower edges of the'portions 56 are located in the grooves 52, respectively, when the terminal members 12 are located in the lower housing-1t A lateral tab 58 extends inwardly from-the upper edge of the terminalportion 44 and can be adapted to-engage the clamping plate 50 to prevent rotation of the latter relative to the terminal portion 44. However, the housing walls 18 and an integral barrier portion 72 can be used perhaps more effectively for this purpose; 'From FIG. it is to be noted that the bottomwall of the lower housing is provided with a raised portion 60'located opposite each terminal opening 40. The shank of the terminal screw is formed to be of such length as to: have the outer end thereof located onthe raised portion- 60. The enlarged head of the terminal screw' 46, as noted previously, is larger than the terminal openings40so that the head cannot pass through the terminal'opening-40. A lead wire is secured to the terminal 12 by passing a bared portion of the lead wire through the opening 42 in the base of the housing 10 until it is located between/the inner surface of the terminal portion 44 and the'clamping plate 50. The terminal screw' 46 is rotated until thelead wire is firmly clamped between the plate 56 and the inner surface of the terminal portion44.

With: this terminal construction, it is to be noted that the clamping plate 50 cannot be'removed from the terminal screwv46 when the terminal'is located in the-lower housing 10. A terminal. construction of this type is more fully described and claimed in the copending" application of Clarence M. Smith, SerialNo... 594,412, filed June 28, 195 6, entitled Wiring Device and'assigned to the present assigne'e. I

' Each combined stationary contact and terminal member 14 is provided with a similar terminal screw 46 and clamping'plate 50'whichare assembled to a portion 59 thereof before each member 14 is inserted'into the lower net surface of each side wall 19 and is formed by an integral raised portion 70 located in the lower housing 10. Similarly, the notch 68 is formed adjacent the inner surface of the side wall 19 by the integral barrier portion 72 located in the lower housing 10. It may, therefore, be seen that the notches 66 and 68 cooperate withthe shoulders 64 to prevent relative movement of the member 14 away from the inner surface of the side wall 19. Inasmuch as the portion 58' of each terminal member 14 is closely received in the lower housing 10 between the raised portions 70 and 72, movement of the member 14 along the longitudinal dimension of the side wall 19 is also prevented.

A central projection 74 is formed integrally with the lower housing 10 and extends outwardly from the base of the lower housing 10 to a position adjacent the open side thereof. The outer end of the projection 74 is provided with an inwardly extending circular guide recess 76 which is adapted to loosely receive and to guide an integral projection 78 which extends outwardly from the under surface of the barrier 24.

The lever 20 is provided with a pair of stiffening ribs 80 which extend laterally outwardly in opposite directions from the side edges thereof, and which cooperate to maintain the lever 20 in a rigid condition. A U-shaped opening 8-2 is formed in the lever 20, creating a resilient contact carrying portion 84. A contact 86 formed from an arc resistant material, such as the aforementioned silver alloy, is secured to the contact carrying portion 84 by suitable means, such, as by riveting or brazing. The outer end edge 32 of the lever 20 is provided with a slight indentation as indicated by the reference character 88 which cooperates with the struck-out projection 34 on the resilient projection 16 of the adjacent terminal member 12 to fixedly yet pivotally locate the outer end of the lever 20 relative to the projection 16.

The lever 22 is similarly provided with oppositely extending lateral ribs 90 located on the side edges thereof to provide rigidity for the lever 22. A u-shaped opening 92, similar to the opening 82 in the lever 20, is provided'in the lever 22.adjacent the inner endedge 30 to form a resilient contact carrying portion 94 thereon. An arc resistant contact 96, similar to the contact 86 of the lever 20, is provided on the contact carrying portion 94 of the lever 22. Adjacent. the outer end 38- of the lever 22 is an enlarged blanked opening 98 having a slight indentation 100 along the edge 36 thereof which cooperates with the struck-out projection 34 on its adhousing 10; Stationary contacts 60, formed from an arc resistant material such as aisilver' alloy, are secured to an integral, laterally. extending portion 62' oneach terminabmember14 bysuitable means such as by: welding or rivetihgJ The terminal portion 58 of each terminal member: 14 is providedwith a pair of opposed shoulders 64; on opposite side edges thereof which are adapted to be located in aligned notches 66 and 681m the lower housing 10. The notch 66 is located adjacent the injacent terminal member 12 to fixedly yet pivotally locate the edge 36 relative to the projection 16.

Viewing FIG. 1, it may be seen that the switch parts heretofore mentioned are assembled with the lower housing 10 in the following manner. The terminal screws 46 are passed through the aligned openings in the terminal portions 58 of the members 14 and the openings in the clamping plates 50, respectively. The terminal screw 46 is tightened until the plate 50 is located adjacent the inner surface of the terminal portion 58. Similarly, the terminal screws 46 and the clamping plates 59 are assembled with the terminal portions 44 of the members 12. The terminal members 12 are then inserted into the lower housing 10 until the portions 56 thereof are located in the respective grooves 52 of the housing 10. When so inserted, the terminal screws 46 are exposed to the exterior of the lower housing 10 through the side opening 40 and 42. The terminal members 14 are then inserted into the lower housing 10 through the open side thereof with the terminal portions 58 being closely adjacent the inner surfaces of the sidewall 19 and the openings 40, respectively. The terminal members 14 are inserted downwardly along the inner surface of the side walls 19 until the shoulders 64 thereof are located in the slots 66 and 68 of the housing 10.

It is to be noted that when the terminal members 12 are so inserted into the lower housing 10, the resilient projections or arms 16 thereof extend outwardly from the open side of the housing and are located adjacent the inner surface of the end walls 18 thereof in opposed relation. The insulating barrier 24 is mounted on the lower housing 10 with its projection 78 located in the recess 76 of the housing barrier 74 and with each groove 26 of the barrier 24 facing one of the resilient arms 16. The lever is assembled with the elements so far assembled by locating the inner edge 28 thereof in one of the grooves 26 of the barrier 24. The outer edge 32 is passed downwardly along the longitudinal dimension of the adjacent arm 16 until the indentation 88 thereon passes over the arm projection 34. Similarly, the inner edge of the lever 22 is located in the other groove 26 of the barrier 24 and the edge 36 of the lever 22 is inserted longitudinally along the inner surface of its adjacent arm 16 until the indentation 36 of the lever 22 is passed over the arm projection 34.

When the levers 20 and 22 are so assembled, one side of the contact 86 of the lever 20 engages the stationary contact 60 of one of the terminal members 14, and one side of the contact 96 of the lever 22 engages the contact 60 of the other terminal member 14. As the contacts 86 and 96 are located on resilient portions of the levers 20 and 22, respectively, it may be seen (FIG. 3) that the engagement of the contacts 86 and 96 with the stationary contacts 60, respectively, are under substantial pressure since the resilient contact carrying portions 84 and 94 are stressed. Such contact pressure is created by the cooperation of a number of elements of this invention. When the switch portions are in the aforesaid position, it is to be noted that the inner edges 28 and 30 of the levers 20 and 22 are located inwardly of the lower housing 10 relative to the outer edges 32 and 36 thereof. Furthermore, the resilient arms 16 of the terminal members 12 exert a force longitudinally along the levers 20 and 22 in the direction laterally inwardly of the housing 10. The switch parts are constructed so that the contacts 86 and 96 engage the stationary contacts 60, respectively, before the barrier 24 engages the outer end of the housing projection 74. As the switch mechanism is in an unstable position until the barrier 24 engages the projection 74, the barrier 24 will move inwardly of the lower housing 10 until it reaches a stable position, thereby stressing the resilient portions 84 and 94 of the levers 20 and 22, respectively.

The open side of the lower housing 10 is provided with a pair of opposed flanges 102 which extend along a portion of the inner periphery thereof. A mounting strap or yoke 104 is provided for the wiring device and is formed from any suitable material having sufiicient strength characteristics such as sheet steel. The yoke 104 is provided with an enlarged planar central portion 106 having an enlarged irregularly shaped opening 108 there in. Four laterally extending resilient arms 110 extend upwardly from the central yoke portion with a pair of resilient arms 110 being located at each end of the central portion 106 and spaced at opposite sides of a securing portion 112. The securing portions 112 are located at opposite ends of the central portion of the yoke 104 and extend laterally outwardly therefrom in the same direction as the resilient arms 110 and then longitudinally outwardly from the central portion 106 in a parallel plane relative to the plane of centralportion 106. Suitable openings 114 and 116 are provided in each of the securing portions 112 for the purpose of mounting the wiring device to a suitable mounting plate or support. The particular shape of the yoke 104 and the function of the resilient arms 110 and the mounting openings 114 and 116 are described in detail in my copending application with C. D. Baxendell, entitled Wiring Device, Serial No. 801,660, filed concurrently with the instant application and assigned to the same assignee as this application.

As shown in FIG. 2, the yoke central portion 106 is adapted to engage the open side of the lower housing 10 with the flanges 102 projecting through the opening 108 thereof. The open side of the lower housing 10 is provided with a pair of mounting portions 118 extending outwardly from the ends of the housing 10 coplanar with the open side thereof and having securing openings 120 extending therethrough, respectively. The opening 108 in the yoke 104 is shaped to expose the securing openings 120 to the outer surface of the yoke 104 when the yoke is in position.

The open side of the lower housing 10 is enclosed by an upper housing 122 and a switch actuator 124. The inner side 126 of the upper housing 122 is complementarily shaped relative to the open side of the lower housing 10-and is provided with threaded openings 128, as viewed in FIG. 4, extending inwardly therefrom which are alignable with the securing openings .120 in the lower housing 10. Thus, the lower housing 10, upper housing 122 and yoke 104 are secured together by passing suitable securing means such as screws (not shown) through the aligned openings 120 and 128 to threadedly engage the openings 128. The yoke 104 is thereby fixedly clamped between the lower housing 10 and the upper housing 122.

The upper housing 122 is forrmed from a suitable insulating material such as the same material used for form ing the lower housing :10 and is of generally open construction. The top surface of the upper housing 122 is provided with a pair of outwardly extending flanges 130 etxending along the entire side edges thereof and forming a longitudinal central groove 132 in the top surface of the upper housing 122. -An enlarged opening 134 extends inwardly from the bottom surface of the groove 132 into the upper housing 122 adjacent one end thereof and a central opening 136 also extends into the upper housing 122. The central opening 136 is provided with extensions which form downwardly extending opposed slots 13-8 in each of the flanges 130. The slots 138 and the flanges 130 cooperate to form an inwardly facing shoulder 140 on the upper housing 122. Viewing FIG. 4, it may be seen that the left-end surface of the upper housing 122 is provided with a pair of spaced slots 142 located on opposite sides of an outwardly extending projection 144. As will be described more fully hereinafter, the projection 144 is adapted to be received in the enlarged opening 98 in the lever 22.

From FIGS. 4 and 5, it is to be noted that the underside of the top surface of the upper housing 122 is provided with a downwardly extending projection 146 located adjacent each corner thereof. Each projection 146 is located inwardly of the lower housing 10 relative to the location of the terminal portion 58 of the terminal mem bers 14 and each projection 146 located adjacent the members 14 overlies an upwardly extending tab 63 on the terminal members 14 to limit inward and outward movement of the terminal members 14 relative to the housing 10. Similarly, the projections 146 adjacent extensions 13 the terminal members 12 overlie the extensions 13 to prevent withdrawal of the terminal members 12 from the housing 10.

The actuator 124 is an elongated member and is preferably formed from an insulating material, such as the same insulating material utilized in forming the upper' and lower housings 10 and 122. -As seen in FIG. 4, the longitudinal dimension of the actuator 124 is larger than the longitudinal dimension of the housings 122 and 10 so that the ends of the actuator 124 extend outwardly from the opposite ends of the upper housing 122. An in, tegral outwardly extending projection 148 is located midway along each side of the actuator .124 with the outer end thereof terminating in an apex 150. A portion of each projection 148 extends outwardly beyond the lateral dimension of the actuator 124 to form a shoulder 152 thereon. Each of the projections 148 are joined on the underside of the actuator 124 by a bridging projection 154 as shown in FIGS. 3 and 4. A cam surface 156exand is located midway between the bridging projection 154 and the left-hand end of the actuator7124 (FIG. 3). The cam surface 156 is also located midwaybetween'the sides of the actuator 124 and terminates in an apex 158 which is adapted to engage anintermediate portion of the lever 20 as hereinafter described;

Referring now to FIGS. 1,' 3 and 4, it is to be noted that, adjacent the right-hand end edge of the actuator 124, there is provided a pair of outwardly extending projections 160 located in thecorners of the actuator 124in opposed relation. The side edges of the projections 169 locatedv at the end edge of the actuator 124 are joined by a cam surface 162 which is adapted to engage the outer end of the lever 22. The outward end of the cam surface 162 terminates in an apex 164 located at the inward extent of the end of the actuator 124.

The width of the actuator 124 is slightly less than the width of the groove 132 of the upper housing '122 and the actuator 124 is adapted to' be received therein. It is to be noted that the distance between the innermost edges of the slots 138 is slightly larger than the distance between the projections 148 of theactuator 124 so that the projections 148are locatable within theslots 138;

To assemble the actuator with the upper hous'i ng 122, the actuator 124 and the housing 122 are aligned so that the projections 160 of the actuator 12.4 are located at the end of the upper housing 122; having the slots 142 therein. The actuator projections 148 are inserted" into the housing slots 138 so that the shoulders 1 52 are located inwardly of the upper housing 122 relative to the location of the housing shoulders 140. The actuator 124 is moved longitudinally until the actuator shoulders 152 and housingshoulders 140 are in opposed relation, respectively. The apexes 150 of the projections 148'are adapted to be received in notches 164 formed in the flanges 102 of the lower housing 10 and the upper'housing 122, with theactuator 124 assembled therewith, is mounted on the lower housing .10 wtih the apexes 150 so located and with the actuator projection 144' located in the opening 98 of the lever 22. Upon securing the'upper and lower housings together in the atoredescribed manner, the switch assembly will have been completed. 7

As" seen in' FIGS. 3', 4, 6 and 7, openings" 210- can be provided in the actuator having resilient means 2 12 located in the undersurface of the actuator adjacent each opening 210 for the purpose of assembling a platetype actuator to the actuator 124. For a detailed description of the utility of the openings 210 and the resilient means 212 and the cooperation thereof with a plate-type actuator, reference is made to my aforesaid copending application.

Viewing FIG. 3, it is to be noted' that the bridging projection1S4 of the actuator 124 is located directly above the insulating barrier 24. Furthermore, the apex 158 of the cam surface 156 engages an intermediateportion of the lever 20 and the apex of the cam surface 162 cugages the outward end of the lever 22% As can be seen, the switch construction including the lever-20 can be likened to a third cl-ass lever system wherein the end edge 32 of'the lever 201s the fulcrum, the apex 158 places an action force on the lever 20 andthe contact 86 and/or inward edge 28 of the lever 20 absorbs the reaction force of the lever system. On the other hand, the construction including the lever 22 can be likened to a first-class lever system with the fulcrum disposed at the edge 36 of the lever 22, the action force provided by the cam surface 162, and the reaction force absorbed at either the contact 96 or the inward edge 30 of the lever 22.

Suflicient clearance is provided in the upper and lower housings'ltl and 122 to allow slight relative pivotal movement of the actuator 124'in'the housings about the apexes 150. When the switch is in the position shown in FIG. 3, it is to be noted that a downward force exerted on the 8 right-hand end of the actuator 124 will cause the outward end of the lever 22 to be moved downwardly thereby moving both the inward ends of the levers 22 and 20 and the barrier 24 upwardly so-that the contact 86 separates from the contact 60. The levers 20 and 22 are then located in the position shown in FIG. 7 as continued upward movement of the inward ends of the levers 2i} and 22 and of the barrier 24 is prevented by the projection 154 on the actuator 124.

The switch, when in the position shown in FIG. 7, is moved to the position shown in PEG. 3 by pressing the left-hand end of the actuator 124' downwardly so that the apex 158 of the actuator cam surface 156 engages an intermediate portion of the lever 20, to move the levers 20 and 22 and the barrier 24 downwardly.

It is to be noted that the embodiment of the invention shown in FIGS. 1 and 2 includes two terminal members 14 having stationary contacts 16 thereon while the switch structure shown in FIG. 3 includes only one terminal member 14.

Referring now to FIGS. 7 and 8, it is to be noted that the embodiment shown therein includes one terminal member 14 having a stationary contact 60 and one combined contact and terminal member 200 (FIG. 8). The combined contact and terminal member 200 is in part constructed exactly as the combined contact and terminal member 14, in that a stationary contact -60 is provided on a contact supporting portion 62'. Additionally, the member 20s includes a terminalportion 58' having one shoulder 64' on one side thereof'and a tab 63' adjacent the contact supporting portion 62'. There is substituted for the other shoulder 64 of the member 14 an irregularly shaped arm 202 having a shoulder 204 in the place of the other shoulder 64. The shoulder 204 is adapted to be located in oneof the recesses 68 of the lower housing 10 in the same manner as one of the shoulders 64 of the terminal member 14. The arm 292 terminates in a laterally extending contact supporting portion 206 having a contact 208 thereon which extends downwardly offset from yet in opposed relation to the contact 60. The contact supporting portion 296 is located in a plane parallel to the plane formed by the contact supporting portion 62', but is located a distance above the plane of the contact supporting portion '62. As seen in FIG. 7, the arm 202 of the terminal member 2% is formed so that the contact supporting portion 266 thereof is located in alignment with the contact supporting portion 62 of the terminal member 14. Thus, the contact 208 of the combined member 200 is located in alignment with and facing the contact 60 of the combined member 14. V

Utilizing the, embodiment of the'invention shown in FIG. 7, it is to be noted that when the levers 20 and 22 are located in the position shown in FIG. 7, the contact 96 of the lever 22 engages the contact 298 of the combined member 280. When the levers are in their other stableposition, the other side of the lever contact 96 engages the contact 60 of the terminal member 14 and the contact 86 of the lever 22 engages the contact 60 of the terminal member 200. u

It may therefore be observed that the switch construction shown in FIGS. 1 and 2 provides a double-pole, single-throw switch and the construction shown in FIG. 3 results in a single-pole, single-throw switch. Furthermore, the switch construction shown in FIG. 7 comprises a switch which may be utilized for single-pole, double throw or three-way switch applications. It is also to be noted that a combined member 200 may be substituted for each of the terminal members 14 shown in FIGS. 1 and 2. so that a four-way switch will result. It is of interest to see that no matter what type of switch is desired, the same switch structure, including the upper and lower housings, the actuator, the yoke, and the levers, is utilized. Thus, the only changes that need be made to vary the type of switch are merely changingthe type and number of terminal members 14 or 200. Additionally, for certain applications, the contacts 86 and 96 on the levers 20 and 22, respectively, would be provided with a single head or a double head depending upon the type of stationary contacts utilized. An example of a lever having a single head contact is shown in FIGS. 3 and 5, while an example of levers having double head contacts is shown in FIG. 7.

It is to be noted that when utilizing the combined terminal member 200 in a wiring device, the portion 135 of the upper housing 122 located between the openings 134- and 136 is positioned so that its undersurface engages the contact supporting arm 206 of the combined member 200 to aid in non-movably locating the combined memher 200 in the upper and lower housing and 122, respectively.

When the switch is in the position shown in FIG. 7, it may be seen that not only is the apex 158 of the cam surface 156 utilized to move the levers 20 and 22 to the position shown in FIG. 3, but the bridging projection 154 of the actuator 124 also exerts an inward force on the outermost surface of the barrier 24. It is to be further noted that very little angular travel of the actuator 124 is required to move the contacts from one position to another. A switch has been constructed in accordance with the teachings of the instant invention whereby merely 3 of angular travel of the actuator 1 24 was required to change the position of the contacts. This construction lends itself for use in combination with an enlarged plate type actuator such as the one shown and described in my aforementioned copending application.

It is to be further observed that when the contacts are in a horizontal position, the levers are in an unstable condition so that it is virtually impossible to tease the contacts so that they remain in a position other than the extreme upper or the extreme lower position, after an external force has been removed from the actuator 124-.

By placing the contacts of the levers 20 and 22 on resilient portions thereof, it is to be noted that sufficient contact pressure between these contacts and the stationary contacts in the switch housing is obtained since engagement of the contacts takes place before the barrier 24 is in either of its extreme positions. The placing of the movable contacts on resilient members also compensates for any misalignment of the components of the switch due to manufacturing tolerances.

It is of utmost importance that wiring devices of the type described herein be manufactured at low cost. To this end, the wiring device constructed in accordance with the principles of the present invention are formed by merely blanking or molding the component parts. Thus,

a build of tolerances is reduced to a minimum since all critical tolerances are either blanking dimensions or molding dimensions and are not subject to variables inherent to metal forming.

Another definite advantage of the present invention is that it provides for fast spring closing of the contacts in all cases. It has been observed that contact life is considerably better with spring closed contacts as compared to contacts requiring a cam backup to ensure contact pressure.

It is to be noted that a portion of the lever 22 extends outwardly from the end of the upper housing 122 through the slots 142. The exposed portion, however, is isolated from the possibility of being touched by any one who operates the switch by the actuator 124 and particularly by means of the cooperation of the projections 160 thereon together with the portions 110 and 112 of the yoke 104 which are located closely adjacent thereto. By providing a lever which extends outwardly of the switch housing, it is to be noted that substantially greater leverage forces can be achieved without increasing the size of the switch housing.

From the foregoing, it is apparent that novel and efiicient arrangements of a wiring device have been disclosed herein. Obviously, numerous embodiments of the invention will occur to those skilled in the art without departing from the broad spirit and scope thereof. Moreover, it is to be understood that certain features of the invention can be employed Without a corresponding use of other features. Accordingly, it is specifically intended that the above description be interpreted in an illustrative rather than in a limiting sense.

I claim as my invention:

1. A wiring device comprising a hollow housing of insulating material, at least one stationary contact fixedly mounted in said housing, an elongated rigid member located in said housing and supported therein by at least a resilient support member and a barrier member, said rigid member having one of its ends pivotally engaging said resilient support member with said resilient support member being stressed to exert a component of force longitudinally along said rigid member, said barrier member being located to pivotally engage the other end of said rigid member, cooperating guide means formed on said housing and said barrier member to allow only limited lateral movement of said barrier member relative to said rigid member between two extreme and stable positions, pivotable actuating means located in said housing to engage an intermediate actuating portion of said rigid memher and to exert a lateral force thereon to move said rigid member and said barrier member pivotally about said one end of said rigid member to one of said extreme positions, additional actuating means formed to move said barrier member and said rigid member pivotally about said one end of said rigid member to the other extreme position of said barrier member and contact means located on said rigid member in a position longitudinally more remote from its one end than is the position of its actuating portion and engageable with said stationary contact when said rigid member is in one of the aforesaid extreme positions.

2. An electric wiring device comprising an elongated hollow housing of insulating material having an open side, an elongated cover memberlocated to enclose said open side of said housing, said cover member including an outwardly facing transverse slot located in the wall portion thereof that is in alignment with said open side, said slot including an extension of less width formed at one side edge thereof and resulting in a pair of spaced inwardly facing shoulders adjacent the ends of said slot, an elongated actuator adapted to be located outwardly of said one wall of said cover member and including a pair of outwardly extending projections located on opposite sides of said actuator, said actuator being of a width between said opposite sides slightly less than the width of said extension with said projections having portions extending outwardly beyond said opposite sides of said actuator, said last mentioned portions being of slightly less width than the width of said slot, said portions forming a shoulder at their juncture with said opposed sides of said actuator, said projections being locatable in said slot with their outward extent engaging a portion of the open side of said housing, said actuator being movable longitudinally relative to said cover so that said last mentioned shoulders are in opposed relation to said housing shoulders, means for securing said housing and said cover together when said actuator is in said last mentioned position, circuit opening and closing means located in said housing and means formed on said actuator located to operate said circuit opening and closing means.

3. An electric wiring device comprising a pair of elongated rigid members mounted in juxtaposed end to end relationship, a pair of resilient support members engaging the opposite outer ends of said rigid members and biasing said members inwardly, respectively, insulating means formed to engage the juxtaposed inner ends of said rigid members to maintain said rigid members separated, one of said rigid members having an actuating portion extending outwardly beyond its outer end, pivotable actuating means located to alternately engage said actuating portion of said one rigid member and an inward actuating portion of the other rigid member to move said members and said insulating means laterally to alternate stable positions, at least one contact secured to one of said rigid members in a position longitudinally more remote from its outer end than is the position of its actuating portion and a stationary contact fixedly located adjacent said one contact and engageable therewith when said one rigid member is in one of its stable positions.

4. A wiring device comprising a hollow housing of insulating material, at least one stationary contact fixedly mounted in said housing, a pair of resilient members located in said housing in spaced opposed relation, apair of elongated rigid levers mounted in juxtaposed end to end relation, one of said levers having its outward edge pivotally engaging an inwardly facing side of one of said resilient members, the other of said levers having an outwardly facing intermediate edge pivotally engaging the corresponding side of the other of said resilient members so that an outward actuating portion of said other lever is located on the other side of said other resilient member, an insulating barrier located between the inward ends of said levers with said inward ends pivotally engaging opposite sidesof said barrier, said resilient members cooperating to exert a force having a component longitudinally along said levers, guide means formed in said housing cooperating to permit movement of said barrier only laterally with respect to said levers, an elongated actuator pivotally mounted on said housing having cam surfaces thereon located to engage alternately an intermediate actuating portion of said one lever and said out- 'ward actuating portion of said other lever, respectively, in response to pivotal movement of said actuator to laterally move said levers alternately to stable positions and at least one contact mounted on one of said levers in a position longitudinally more remote from itspivotally engaged edge than is the position of its actuating portion and located to engage said stationary contact when said last mentioned lever is in one of its stable positions.

5; A wiring device comprising a hollow housing of insulating material, a pair of resilient members located in said housing in spaced opposed relation, a pair of elongated rigid levers mounted in juxtaposed end-to end relation, one'of said levers having its outward edge pivotally engaging an inwardly facing side of one of said resilient members, the other of said levers having an outwardly facing intermediate edgepivotally engaging the corresponding side of the other of said resilient members so that an outward actuating portion of said other lever is located, on the other side of said other resilient member, an insulating barrier located between the inward ends of said levers with said inward ends pivotally engaging opposite sides of said barrier, said resilient members cooperating to exert a'force having a component longitudinally along said levers, guide means formed in said housing cooperating to permit movement of said barrier only laterally with respect to said levers, an elongated actuator pivotally mountedon said housing having cam surfaces thereon located to engage alternately an intermediate actuating portion of said one lever and said outward actuating portion of said other lever in response to pivotal movement of said actuator to laterally move said levers alternately to stable positions, each of said levers having an integral resilient portion formed thereon, one of said resilient portions having a contact secured to opposite sides thereof, the other resilient portion having a contact secured to one side thereof, said contacts being positioned longitudinallytmore remotely from the respective pivotally engaged lever edges than are said lever actuating portions, a pair of stationary contacts fixedly mounted in said housing, one of said contacts being located to engage the contact located on one side of said one resilientportion when said levers are in one of their stable positions, the other of said stationary contacts being located to 12 engage the-contactlocated on said other re'silie'ntportion when said levers are in said one stable position, said other stationary contact also including an integral extension located to engage the contact located on the other side of said one resilient portion when said levers are in their other stable position.

6. A wiring device comprising a housing of insulating material, a pair of elongated lever members being positioned substantially in end-to-end relation, support means for pivotally supporting an outer portion of each of said lever members relative to said housing and for forming a toggle system which includes said lever members, an elongated actuating member and means for pivot ally supporting the same upon said housing over said lever members, said actuating member having one cam portion engageable with an actuating portion of one of said lever members'to urge said toggle system overcenter in one direction and a' second cam portion spaced from said one cam portion engageable with an actuating por tion of the other of said lever members to urge said toggle system overcenter in the direction opposite said one direc tion, and separable contact means being supported in said housing and on at least one of said one and said other lever members in a position more longitudinally remote from its outer portion than is the position of its actuating portion to provide for opening and closing a circuit in response to the overcenter movement of said toggle system.

7. A wiring device comprising a housing of insulating material, and means for making and breaking a circuit, said circuit making and breaking means including at least one elongated lever member and support means for pivotally supporting one portion of the same relative to said housing and for forming a toggle system which includes said lever member, pivotable actuating means for engaging an actuating portion of said lever member to urge said toggle system over-center in one direction and for engaging said toggle system to urge the same overcenter in the direction opposite said one direction, and separable contact means being supported'in said housing and on at least said lever member in a position more longitudinally remote from said one portion than is the position of said actuating portion.

8. A wiring device comprising a housing of insulating material, and means for making and breaking a circuit, said circuit making and breaking means including at least one elongated lever member and support means for pivotally supporting one portion of the same relative to said housing and for forming a toggle system which includes said lever member, said support means including at least one terminal member having a resilient arm engaging said one portion of said lever member to provide resilient forces longitudinally of said lever member -for urging the latter to undergo longitudinal movement, said terminal member with an integral portion having means for engaging conductors, and pivotable actuating means for engaging an actuating portion of said lever member to urge said toggle system overcenterin one direction and for engaging said toggle system to urge the same overcenter in the direction opposite said one direction, and a contact being provided on said lever member in a position more longitudinally remote from said one portion than is the position of said actuating portion.

9. A wiring device comprising an elongated hollow housing of insulating material, one outwardly facing side of said housing including with a transverse slot an extension of less width formed at one side edge thereof to provide a pair of spaced inwardly facing shoulders on said housing adjacent the ends of said slot, an elongated actuator adapted to be positioned outwardly of said one housing side and including a pair of lateral projections being insertable through said slot so as to be positioned under said housing shoulders upon longitudinal movement'of said actuator after insertion of said lateral projections through said slot, means for pivotally supporting said actuating member relative to said housing and for precluding Withdrawal of said actuating member from its inserted position, circuit making and breaking means p0- sitioned in said housing and means formed on said actuator to operate said circuit making and breaking means.

10. A wiring device comprising a housing of insulating material, and means for making and breaking a circuit, said circuit making and breaking means including at least one lever member and support means for pivotally supporting one portion of the same relative to said housing and for forming a toggle system which includes said lever member, contact means being provided on another portion of said lever member, and an elongated actuating member for effecting overcenter movement of said toggle system and means for pivotally supporting said actuating member relative to said housing, said actuating member having a cam portion engageable with an actuating portion of said lever member which is spaced from said one portion a distance which is so proportioned to the distance between said other portion and said actuating portion as to enable the overcenter movement of said toggle system to be obtained with pivotal movement of said actuating member through an angle on the order of a few degrees.

References Cited in the file of this patent UNITED STATES PATENTS 1,439,231 Erickson Dec. 19, 1922 1,790,974 Cox Feb. 3, 1931 2,285,887 Bendander June 9, 1942 2,501,456 Thias et al Mar. 21, 1950 2,748,214 Immel May 29, 1956 2,985,730 Wiley May 23, 1961 

